Although AC7120 is an audit requirement for the process compliance of PCB assembly manufacturing, several basic requirements are universally applicable to other production line controls, such as:

a) Personnel requirements: Operators and inspectors should be IPC certified, with proof of vision inspection; familiarity with various specifications and positions; work as required.

b) Material requirements: Specified in design drawings; comply with ESD (Electrostatic Discharge) and MSD (Moisture Sensitive Device) control; manage expiration dates, opening expiration dates, and subcontract expiration dates; institute acceptance required; periodic testing during use.

c) Equipment requirements: Maintenance checklist; authorized personnel to operate; configure monitoring devices; test and save data every shift.

d) Process requirements: Adhere to international or industry standards; confirm and test after each process; control procedures; ensure rationality of process methods.

e) Environmental requirements: Control temperature, humidity, ESD in EPA (Electrostatic Protected Area), noise, illuminance, and cleanliness.

These documents will be reviewed by the auditor and verified item by item during the on-site audit.

2.2 Quality Control Requirements

2.2.1 Quality System Focus

AC7120 audits are based on the implementation of the unit’s quality management system requirements, including quality manuals, procedures and document control, personnel qualifications, environmental requirements, material control, supplier control, first article appraisal, non-conforming product management, corrective measures, QA personnel, and internal audit effectiveness, combined with process audit requirements, and require implementation evidence.

2.2.2 Effectiveness of Corrective Measures

Ensure effective implementation of corrective measures for non-conformities identified in previous reviews and verify the results. Ineffective or unmaintained corrective measures can lead to two serious non-conformities: repeated problems and failure to sustain corrective measure effectiveness.

2.2.3 Traceability

Materials must be traceable to the original manufacturer’s batch number; COC must be attached to the first article report. All on-site materials must have sub-packaging labels indicating: material name, specification, original packaging validity period, batch number, opening validity period, subcontractor, and material batch number must align with the work order. Maintain all product files permanently and keep on-site production records for over 5 years.

2.3 Process Professional Requirements

2.3.1 ESD Control

Control of the EPA area includes ensuring hardware (floor mats, chairs, etc.) is anti-static, grounding equipment, and using anti-static materials (e.g., turnover boxes, trash cans, tweezers). If anti-static materials cannot be used, an ion fan should be used during operation. Use anti-static pockets for ESD materials, wear anti-static wrist straps when handling them, and inspect anti-static shoes and wrist straps daily.

2.3.2 MSD Control

Identify the level of humidity-sensitive devices, dry according to factory instructions before assembly, and follow workshop life recommendations for assembly and use.

2.3.3 PCBA Cleaning

PCBA requires cleaning after single-board debugging. Cleaning should be performed within 8 hours post-soldering as per NADCAP AC7120 to effectively remove flux. Consider vapor phase cleaning to mitigate the impact on production cycle times if water or semi-aqueous cleaning is used, which requires a 4-hour drying time.

2.3.4 Rework and Repair Control

NADCAP AC7120 stresses that rework is not allowed, and customer approval is required for repairs. The effectiveness of on-site execution will be the focus of the audit, including accurate traceability, proper execution of processes, complete records, and accessible, current guidance documents. All requirements must be met as promised by the organization.